Corrugated shipping pallet

Abstract

A lightweight pallet, which can be manufactured from corrugated paper or similar materials which are recyclable, is disclosed for carrying goods and materials. The pallet includes an upper deck member, lower deck member and a plurality of support members connected therebetween. The deck members are independently disposed at a horizontal plane substantially parallel to each other as well as a ground surface. The support members are formed from a continuous wind of a single sheet of corrugated paper to, provide strength and rigidity to the pallet.

What is claimed is:  
     
       1. A pallet, comprising; 
       an upper deck member formed from a corrugated sheet;  
       a lower deck member formed from a corrugated sheet; and  
       at least two support members, each support member being a solid wind of contiguous layers of one or more corrugated sheets and each said support member having a predetermined height, said support member having a central layer of a predetermined length and additional said contiguous layers wrapped around said central layer, said support members connected to both said deck members so that said deck members are substantially parallel to each other.  
     
     
       2. A pallet according to  claim 1 , wherein said support member corrugated sheet comprises a single paper layer to which a layer of flutes are attached, and wherein said flutes are arranged in a substantially vertical direction to the plane of said deck members. 
     
     
       3. A pallet according to  claim 2 , wherein said support member is connected to said deck members with an adhesive or fastener, and wherein each support member, independently, is a wind of about 6 or less of said corrugated sheets. 
     
     
       4. A pallet according to  claim 3 , wherein said corrugated sheets of said deck members comprise single wall, double wall, or triple wall corrugated sheets. 
     
     
       5. A pallet according to  claim 4 , wherein said deck member flutes are arranged in a direction perpendicular to the longest length of said support member. 
     
     
       6. A pallet according to  claim 5 , wherein each support member, independently, is a continuous wind of 2 or less corrugated sheets, and wherein said flutes of said deck members are arranged perpendicular to the flutes of said support members. 
     
     
       7. A pallet according to  claim 6 , wherein said support members include curved end portions and are formed from a single sheet of corrugated paper, and wherein each said support member length extends substantially the length of said deck members. 
     
     
       8. A pallet according to  claim 1 , wherein said upper deck member and said lower deck member have a length of from about 12 to about 50 inches and a width of from about 12 to about 50 inches, and wherein said support members have a height of from about 3 to about 6 inches, and wherein each said support member length extends substantially the length of said deck members. 
     
     
       9. A pallet according to  claim 1 , wherein said lower deck member includes a plurality of jack holes, and wherein each said support member includes at least two cut-outs which extend completely through the width of the support member. 
     
     
       10. A method for forming a pallet, comprising the steps of: 
       forming a solid support member from a single sheet of corrugated paper by continuously wrapping a predetermined number of contiguous layers around a central layer, said support member having a predetermined height width, and length;  
       forming at least a second support member; and  
       connecting an upper deck member and a lower deck member to said support members with said support members being disposed between said deck members, said deck members being formed from corrugated sheets.  
     
     
       11. A method according to  claim 10 , wherein said support member corrugated paper comprises a single paper layer having a layer of flutes attached thereto, and wherein said support member flutes are arranged in a substantially vertical direction with respect to at least one said deck member. 
     
     
       12. A method according to  claim 11 , wherein said support member is connected to said deck members with an adhesive or fastener. 
     
     
       13. A method according to  claim 12 , wherein said deck members comprise single wall, double wall, or triple wall corrugated sheeting. 
     
     
       14. A method according to  claim 13 , wherein said deck member flutes are arranged in a direction substantially perpendicular to the length of said support member. 
     
     
       15. A method according to  claim 14 , wherein said support members include curved end portions, and wherein each said support member length extends substantially the length of said deck members. 
     
     
       16. A method according to  claim 15 , wherein a plurality of jack holes are formed in said lower deck member, and wherein each said support member includes at least two cut-outs which extend completely through the width of the support member. 
     
     
       17. A pallet, comprising: 
       an upper deck member formed from a corrugated sheet;  
       a lower deck member formed from a corrugated sheet; and  
       a support member comprising one or more pieces of corrugated paper comprising a) a single layer of paper having a length, a width, and a height, and b) flutes connected to said single layer of paper, said flutes arranged parallel to said single layer paper height, said support member being solid and having a central layer of a predetermined length formed from said corrugated paper, and said corrugated paper further wrapped in contiguous layers around said central layer to form said support member having a predetermined height, said support members connected between said deck members so that said deck members are substantially parallel to each other.  
     
     
       18. A pallet according to  claim 17 , wherein each said support member length extends substantially the length of said deck members. 
     
     
       19. A pallet according to  claim 18 , wherein each said support member includes at least two cut-outs which extend completely through the width of the support member. 
     
     
       20. A pallet according to  claim 19 , wherein each said support member is formed from a single piece of corrugated paper.